CN113557125A - 用于在由塑料制成的结构构件与金属部件之间建立接合连接的方法 - Google Patents

用于在由塑料制成的结构构件与金属部件之间建立接合连接的方法 Download PDF

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CN113557125A
CN113557125A CN202080020144.7A CN202080020144A CN113557125A CN 113557125 A CN113557125 A CN 113557125A CN 202080020144 A CN202080020144 A CN 202080020144A CN 113557125 A CN113557125 A CN 113557125A
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metal part
structural component
microstructure
plastic
component
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CN113557125B (zh
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M·拉肯布林克
J·D·文策尔
T·威斯
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Hella GmbH and Co KGaA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
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    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
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    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
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    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
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Abstract

本发明涉及一种用于在车辆的照明装置的结构构件(1)与金属部件(2)之间建立接合连接的方法，其中，所述方法至少包括以下步骤：在金属部件(2)的接合面中产生微结构(10)，其中，微结构(10)关于所述接合面具有侧凹部，借助于热引入使塑料构件(1)的在互补的接合面的近表面区域中的塑料材料软化，用压力(F)将塑料构件(1)和金属部件(2)彼此压靠，使得软化的所述塑料材料的一部分进入微结构(10)的侧凹部中，并且冷却塑料构件(1)的塑料材料，以形成塑料构件(1)的软化的所述塑料材料的恢复的强度。

Description

用于在由塑料制成的结构构件与金属部件之间建立接合连接 的方法
技术领域
本发明涉及一种用于在车辆的照明装置的由塑料制成的结构构件与金属部件之间建立接合连接的方法。
背景技术
由DE 10 2014 109 114 A1已知一种在由塑料制成的构件和金属部件之间的接合联合体。为了将塑料构件与金属部件连接，例如示出在第一侧上的卡钩和在相对的第二侧上的螺纹元件。该实例说明，在构造用于车辆的照明装置时，塑料构件与金属部件之间的连接通常是耗费的并且需要多个附加构件，其中，在避免几何形锁合连接、如卡钩等时和/或在避免螺纹元件、备选地粘合连接或夹紧连接时使用。使用如弹簧等的保持元件也是常见的。由此不利地得到接合连接的耗费的设计方案和装配，并且通常需要多个附加构件或附加材料如螺栓、弹簧或粘接剂等。
当例如在螺纹连接或铆接连接的情况下产生点状的力传递连接时，产生另外的缺点，所述力传递连接在复合结构的机械负荷的情况下产生。该连接部分地承受高负荷，并且材料、即塑料或金属可能在连接区域中承受高的局部应力。由此产生不期望的变形，这种变形尤其在公差很小的情况下应当避免；这也涉及到在光技术上起作用的构件如发光器件支架、反射器、透镜、光导体等的位置和布置。
由DE 10 2017 214 518 A1已知一种用于建立接合连接的方法，其中，铸造的部件与金属结构元件连接。在此，必须例如通过粉末床方法、通过选择性激光烧结或选择性激光熔化来生成式地制造金属结构元件。金属结构元件的表面具有包括微型凹陷的表面结构，铸造部件的铸造材料可以进入到该微型凹陷中。由此在金属结构元件和浇铸的部件之间产生形锁合的、面状构造的微型连接。不利的是，所提出的连接技术的可应用性仅是有限的，因为不是每个金属结构元件都能够在生成式的方法中制造；此外，尤其不是出于成本原因，并且在没有在结构元件和铸造的部件之间形成形锁合的情况下，还不知道该方法的更广泛应用。在这里，这些接合部件形锁合地彼此接合。
发明内容
本发明的任务在于，改进一种用于在机动车的照明装置的由塑料制成的结构构件与金属部件之间建立接合连接的方法。在此，该方法应以简单的方式导致这样的接合联合体，该接合联合体在机械上可以被加载大负荷，该接合联合体尽可能是气密且液密的并且不会在结构构件和/或金属部件中引起点状的高负荷。此外，期望的是，通过用于建立接合连接并且因此制造接合联合体的方法，能够以简单的方式实现紧密的公差的保持，而不需要任何后续的调校操作。
所述任务从根据权利要求1的方法出发并且从根据权利要求11的接合联合体出发利用相应的特征部分的特征来解决。本发明的有利的改进方案在从属权利要求中给出。
根据本发明的用于在车辆的照明装置的由塑料制成的结构构件和金属部件之间建立接合连接的方法建议以下步骤：在所述金属部件的接合面中产生微结构，其中，所述微结构关于所述接合面具有侧凹部；借助于热引入使结构构件的在互补的接合面的近表面区域内的塑料材料软化；用压力将结构构件和金属部件这样地彼此压靠，使得一部分软化的塑料材料进入微结构的侧凹部内，并且将结构构件的塑料材料冷却，以形成结构构件的软化的塑料材料的恢复的强度。当然，在实际接合过程之前同样可以使金属部件升温，从而当两个接合伙伴建立接触时，由塑料制成的结构构件不会在金属部件上已经立即又被冷却。
如果将根据本发明的用于在由塑料制成的结构构件与金属部件之间建立接合连接的方法用于机动车的照明装置中的构造，那么能够以简单的方式借助于由塑料制成的结构构件来构造所述照明装置中的通常敏感的并且位置精确地待安装的光源、透镜、光导体、厚壁光学器件、反射器、发光器件支架等，并且不需要附加元件比如螺栓、夹紧元件或者弹簧。此外，不需要诸如粘接剂等的接合材料。另外的优点是，金属部件相对于由塑料制成的结构构件的相对位置的良好的可调校性。
利用接合连接形成的混合构件可以在照明技术设备、即车辆的照明装置、例如前照灯内形成结构构件并且补偿本身已知的、迄今为止的负面特性。例如可以通过有针对性地定位接合连接来补偿温度漂移，以便例如即使在高机械负荷下也抑制亮暗边界的移位。如果在混合构件上布置有在光学技术上起作用的构件如透镜、反射器、光源等，则尤其在高的机械负荷的情况下或在更强的温度差的情况下该构件以明显更小的程度改变其位置。
照明装置中的接合连接，例如在前照灯中构造光模块时的接合连接，具有改善的特性，尤其是将结构构件紧固在前照灯壳体中或前照灯壳体上或车辆中的接纳结构上，或者附加地或备选地将光学有源构件紧固在一个结构构件上或多个结构构件上。根据本发明的接合连接的优点在于面式连接，而不产生例如在螺纹连接的情况下的点状的接合连接，从而在敏感的光学技术构件中不出现应力峰值。
特别有利的是，借助接触加热元件、借助激光辐射或借助对结构构件的互补的接合面进行红外辐射来产生热引入。互补的接合面形成与金属部件上的接合面相对的面。可设想的是，金属部件被加热并且与结构构件的塑料接触。通过从金属部件向由塑料制成的结构构件的热传递，结构构件的靠近表面的区域在接合面中同样可以被加热并因此被软化，从而软化的塑料材料能够进入到金属部件中的微结构的侧凹部中。此外，也可以通过感应或熔炉储存或通过其他合适的方法进行热引入。
按照根据本发明的方法的另外的有利的设计方案，在将由塑料制成的结构构件和金属部件彼此压靠时以软化的塑料材料形成进入微结构中的材料舌，通过该材料舌与金属部件构成形锁合和/或力锁合。例如，微结构具有在金属部件的表面中的孔、槽或缺口，其相对于表面倾斜地进入到金属部件的本体中。在此，金属部件中的槽或孔的倾斜角可以彼此改变，从而结构构件不能够在拉出方向上从金属部件再次松脱。此外存在的可能性是，例如通过在金属部件内的更大深度处增加微结构的横向尺寸来实施具有侧凹部的微结构本身。这种微结构例如能够通过激光烧蚀或者借助于蚀刻方法制造。微结构的几何尺寸可以例如为10μm至1000μm。
如果材料舌在微结构内部形成，该材料舌尤其也还相对于表面倾斜地延伸，并且以不同的倾斜方向在接合面上分布地定向，则在结构构件和金属部件之间出现形锁合。此外，尤其是通过在塑料材料冷却时、尤其是在材料舌的区域中的轻微的收缩过程可以形成力锁合。结构构件以一定方式由此在金属部件的表面中抓紧。因此持久地并且尤其是液密和气密地建立连接。
金属部件的接合面中的微结构可以具有凹陷或凸起。如果微结构在接合面中突出地实施，那么凸起进入软化的塑料中并且被软化的塑料包围，从而在塑料冷却之后形成形锁合和/或力锁合。
具有另外的优点的是，具有微结构的接合面被选择为大小等于或者小于结构构件和金属部件之间的接触面。因此可以有针对性地提供具有在结构构件与金属部件之间的力传递的面区段，所述面区段可以被设计成，使得在接合区内仅出现小的机械负荷，从而构件之间的实际接触面可以明显大于实际接合面。通过仅局部地应用连接，可以有针对性地在结构构件和金属部件之间产生接触区域，所述接触区域被布置成，使得实现在结构构件和金属部件之间的理想的力传递。接合面被选择成大到使得单位面积负荷在力传递时明显保持在混合构件的尤其塑料部件的损伤极限之下。
此外有利的是，在结构构件和金属部件之间的接触面上形成单个具有微结构的接合面或多个单独彼此分离地构造的、具有微结构的接合面。例如，在光学器件和金属承载体之间的矩形接触面的情况下，在矩形形状的四个角中可以设置接合面，从而不需要全面地加热所述结构构件的表面，而仅需要局部地加热所述结构构件的表面。
具有另外的优点的是，所述金属部件借助镁合金、铝合金、锌合金或铁合金来形成，和/或金属部件借助压铸方法、挤压方法、锻造方法、借助切削制造和/或借助冲压弯曲方法来制造。
此外优选地，利用金属部件形成结构构件的光学器件接纳部、模块框架或保持部，或者利用金属部件形成照明装置的壳体的保持接片，和/或规定，利用所述金属部件形成控制器的壳体或者至少部分地形成车辆的照明装置的壳体或者封闭车辆的照明装置的壳体上的开口。由此，所述控制器能够利用根据本发明的接合连接例如布置在照明装置的壳体中或上的构件上，或者所述控制器本身连接在照明装置的壳体上。
有利地，这样选择在由塑料制成的结构构件与金属部件之间的具有微结构的接合面，使得借助于由塑料制成的结构构件与金属部件之间的不同的热膨胀系数实现对作为框架、作为承载体、作为壳体等的结构构件相对于安装环境的位置的热补偿。
结构构件和金属部件可以具有彼此不同的热膨胀系数，并且接合面可以这样定位在金属部件和结构构件之间，使得例如在作为塑料构件的光学构件的光学技术上的重要的位置公差的方面，通过利用不同的热膨胀系数来补偿温度漂移。
还有利的是，为了制造接合联合体，结构构件和金属部件利用操作系统彼此挤压，其中，在此这样操控操作系统，为了补偿公差而使结构构件的位置定位在金属部件上或金属部件处的补偿位置中。
在近表面的塑料材料还软化期间，结构构件可以在一定限度内相对于金属部件定位。如果结构构件的塑料材料重新冷却，则以一定方式冻结所设定的非常精确的位置，从而持久地保持设定结构构件相对于金属部件的位置公差。
此外，本发明还涉及一种由塑料制成的结构构件和金属部件构成的接合联合体，其中，所述接合联合体以上述方法制造。尤其是金属部件与由塑料制成的结构构件一起构成混合构件，该混合构件本身又可以构成照明装置的结构构件。
附图说明
下面借助于附图连同对本发明的优选实施例的说明一起更详细示出改进本发明的其他措施。在此，示出：
图1示出在由塑料材料制成的结构构件与金属部件之间的接合联合体的示意横剖视图，
图2示出被构造为前照灯的壳体的结构构件和控制器的视图，
图3示出作为壳体的结构构件和由金属部件形成的保持部的视图，以及
图4示出前照灯及其壳体的示意图，该壳体形成由塑料形成的结构构件，以及构造在壳体上的保持接片，所述保持接片形成金属部件。
具体实施方式
图1示出在由塑料制成的结构构件1和金属部件2之间的接合联合体的横剖视图。由塑料制成的结构构件1抽象地示出并且因此以未更详细示出的方式构造为承载元件、保持元件或者例如构造为车辆的照明装置、例如前照灯的壳体。金属部件2例如可以形成加固部、保持部、保持接片等。
微结构10被引入到金属部件2的表面中，该表面用作与由塑料制成的结构构件1的接触面，该微结构从该表面开始倾斜地进入到金属部件2的本体中，其中，微结构的倾斜角指向彼此不同的方向，示例性地可见地示出左侧的微结构10以及相反定向的右侧微结构10。
微结构10例如借助激光烧蚀方法或借助蚀刻方法引入到金属部件2中。微结构10的图示相对于金属部件2的厚度被夸大地构造，并且足够的是，微结构10从表面开始以例如小于1000μm、小于500μm或小于200μm的深度进入材料中。
为了产生接合连接，首先例如利用接触加热元件、借助激光辐射或借助红外辐射使由塑料制成的结构构件1的互补的、即与金属部件2相对的接触区域升温。由塑料制成的结构构件1以其接着被软化的表面被压到金属部件2的微结构10上，其中，所施加的压力F用箭头示出。然后，结构构件1的软化的塑料材料的一部分进入微结构10中并形成材料舌11，所述材料舌在塑料构件1冷却之后在侧凹部的微结构10中在一定程度上抓紧并因此形成形锁合并且可能附加地形成摩擦配合。由此，在由塑料制成的结构构件1与金属部件2之间产生可承受机械负荷的接合连接，而不需要宏观的形锁合。
图2示例性示出壳体14的一部分，该壳体形成由塑料制成的结构构件1并且可以是前照灯的壳体14。在壳体14中引入开口28，并且在外侧在开口28前方布置有控制器21，从而控制器21的壳体20示例性地封闭开口28。
控制器21的壳体20示例性地形成金属部件2，该金属部件被接合到结构构件1上，该结构构件1由塑料构造并且通过壳体14形成。
在接合区域中，控制器21的壳体20的表面设有微结构10，从而控制器20利用根据本发明的方法可以布置在前照灯的壳体14的外侧上并且由此还封闭开口28。在壳体14的内部空间中插入有内部的线缆引导部27，所述内部的线缆引导部例如可以与发光器件或与调节驱动器连接，并且控制器21具有外部的线缆引导部29，所述外部的线缆引导部例如可以与车辆本身连接。
通过微结构10限定的接合区域示例性地完全包围开口28，从而该开口在布置控制器21时并且在建立接合连接之后被液密且气密地密封。
在图3中，示意地示出具有壳体14的前照灯的结构，并且在壳体14中接纳有光源12和光学部件22。光学部件22借助光学器件保持部16保持，并且保持部18延伸穿过壳体14，所述保持部从壳体14的侧面向外引导并且具有螺孔26，前照灯例如可以通过所述螺孔紧固在车辆中。光学器件保持部16在此借助接触区段23布置在保持部18上，同样地，光源12借助承载体17接纳在保持部18上。
保持部18示例性地形成金属部件2，并且壳体14形成由塑料制成的结构构件1，所述结构构件具有以根据本发明的方式建立的与保持部18的接合连接。此外，在本发明的意义中，光学器件保持部16借助接触区段23以根据本发明的方式利用接合连接施加在保持部18上，以相同的方式可以将用于光源12的承载体17施加在保持部18上。
图4以示意图示出具有壳体15的前照灯的另外的实例，其中，所述壳体15形成由塑料制成的结构构件1。在壳体15中设置用于接纳光学部件24的光学器件接纳部13，并且在壳体15上布置塑料封闭板。光学器件接纳部13可以形成具有微结构10的区域的金属部件2，通过该金属部件所述光学器件接纳部13以根据本发明的方式被紧固在壳体15的内侧中。
此外，在壳体15的外侧上布置有由金属制成的保持接片19，这些保持接片在与壳体15的接合区域中具有相应的微结构10，保持接片19通过这些微结构与壳体15的塑料材料以根据本发明的方式连接。
本发明在其实施方案方面不限于上述优选的实施例。更确切地说，可以想到多种变型方案，该变型方案在原则上不同类型的实施方案中也使用所示的解决方案。所有由权利要求、说明书或附图得出的特征和/或优点，包括结构上的细节、空间的布置和方法步骤，不仅可以单独地而且可以以不同的组合对于本发明而言都是重要的。
附图标记列表
1 由塑料制成的结构构件
2 金属部件
10 微结构
11 材料舌
12 光源
13 光学器件接纳部
14 壳体
15 壳体
16 光学器件保持部
17 承载体
18 保持部
19 保持接片
20 壳体
21 控制器
22 光学部件
23 接触区段
24 光学部件
25 塑料封闭板
26 螺孔
27 内部的线缆引导部
28 壳体中的开口
29 外部的线缆引导部
30 空腔
F 压力

Claims (12)

1.一种用于在车辆的照明装置的由塑料制成的结构构件(1)与金属部件(2)之间建立接合连接的方法，其中，所述方法至少包括以下步骤：
-在金属部件(2)的接合面中产生微结构(10)，其中，微结构(10)关于接合面具有侧凹部，
-借助于热引入使结构构件(1)的在互补的接合面的近表面区域中的塑料材料软化，
-用压力(F)将结构构件(1)和金属部件(2)彼此压靠，使得软化的所述塑料材料的一部分进入微结构(10)的侧凹部中，并且
-冷却结构构件(1)的塑料材料，以形成塑料构件(1)的软化的所述塑料材料的恢复的强度。
2.根据权利要求1所述的方法，其特征在于，所述热引入借助于接触加热元件、借助于激光辐射或借助于红外辐射来产生。
3.根据权利要求1或2所述的方法，其特征在于，在所述结构构件(1)和所述金属部件(2)彼此压靠时以软化的所述塑料材料形成进入微结构(10)的材料舌(11)，通过所述材料舌而与金属部件(2)形成形锁合和/或力锁合。
4.根据权利要求1至3中任一项所述的方法，其特征在于，具有所述微结构(10)的接合面大小等于或小于在结构构件(1)与金属部件(2)之间的接触面。
5.根据前述权利要求中任一项所述的方法，其特征在于，在所述结构构件(1)与所述金属部件(2)之间的接触面上形成有单个具有微结构(10)的接合面，或者形成有多个单独地彼此分离地构造的、具有微结构的接合面。
6.根据前述权利要求中任一项所述的方法，其特征在于，所述金属部件(2)借助于镁合金、铝合金、锌合金或铁合金来形成，和/或借助于压铸方法、挤压方法、锻造方法、借助于切削制造和/或借助于冲压弯曲方法来制造。
7.根据前述权利要求中任一项所述的方法，其特征在于，利用由塑料形成的所述结构构件(1)形成照明装置的壳体(14、15)、形成透镜保持部(16)、框架体、承载体(17)等。
8.根据前述权利要求中任一项所述的方法，其特征在于，利用所述金属部件(2)形成光学器件接纳部(13)、照明装置的结构构件(1)的保持部(18)或者照明装置的壳体(15)的保持接片(19)，和/或利用所述金属部件(2)形成控制器(21)的壳体(20)。
9.根据前述权利要求中任一项所述的方法，其特征在于，选择在结构构件(1)与金属部件(2)之间的具有微结构(10)的所述接合面，使得借助于在结构构件(1)与金属部件(2)之间的不同的热膨胀系数来实现对结构构件(1)的位置的热补偿。
10.根据前述权利要求中任一项所述的方法，其特征在于，利用操作系统将所述结构构件(1)和所述金属部件(2)彼此压紧，其中，操控所述操作系统，使得为了补偿公差而将结构构件(1)的位置定位在金属部件(2)上的补偿位置中或定位在金属部件处的补偿位置中。
11.一种由结构构件(1)和金属部件(2)制成的接合联合体，所述接合联合体利用根据前述权利要求中任一项所述的方法来制造。
12.根据权利要求11所述的接合联合体，其特征在于，所述金属部件(2)形成结构构件(1)的保持部，和/或所述金属部件(2)形成用于将照明装置保持地接纳在车辆的结构中的保持接片(19)。
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